Komatsu HD1500-8 Dump Truck Shop Manual SEN06630-11 – PDF DOWNLOAD

Komatsu HD1500-8 Dump Truck Shop Manual SEN06630-11 – PDF DOWNLOAD

FILE DETAILS:

Komatsu HD1500-8 Dump Truck Shop Manual SEN06630-11 – PDF DOWNLOAD

Language : English
Pages : 2908
Downloadable : Yes
File Type : PDF
Size: 158 MB

TABLE OF CONTENTS:

Komatsu HD1500-8 Dump Truck Shop Manual SEN06630-11 – PDF DOWNLOAD

INDEX
00 INDEX AND FOREWORD 00 1
ABBREVIATIONS 00 22
FOREWORD, SAFETY, BASIC INFORMATION 00 27
HOW TO READ THE SHOP MANUAL 00 27
SAFETY NOTICE FOR OPERATION 00 29
PRECAUTIONS TO PREVENT FIRE 00 37
ACTIONS IF FIRE OCCURS 00 38
PRECAUTIONS FOR REMOVAL OF DANGEROUS MATERIALS 00 38
STEPS NECESSARY TO MEET EXHAUST GAS REGULATIONS 00 39
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 42
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00 44
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00 52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 53
PRACTICAL USE OF KOMTRAX 00 54
DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER 00 55
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00 59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00 63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 68
HOW TO READ ELECTRICAL WIRE CODE 00 69
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 73
STANDARD TIGHTENING TORQUE TABLE 00 75
CONVERSION TABLE 00 82
01 SPECIFICATIONS 01 1
ABBREVIATIONS 01 3
SPECIFICATIONS 01 8
SPECIFICATION DRAWING 01 8
SPECIFICATIONS 01 12
WEIGHT TABLE 01 24
FUEL, COOLANT, AND LUBRICATING OIL 01 26
10 STRUCTURE AND FUNCTION 10 1
ABBREVIATIONS 10 6
BOOT UP SYSTEM 10 11
LAYOUT DRAWING OF BOOT UP SYSTEM 10 11
SYSTEM OPERATING LAMP SYSTEM 10 14
BATTERY DISCONNECT SWITCH 10 15
ENGINE SHUTDOWN SECONDARY SWITCH 10 16
EXTERNAL POWER SUPPLY ENGINE PREHEATER 10 18
ENGINE SYSTEM 10 21
LAYOUT DRAWING OF ENGINE SYSTEM 10 21
ENGINE CONTROL SYSTEM 10 23
COMPONENT PARTS OF ENGINE SYSTEM 10 27
COOLING SYSTEM 10 28
LAYOUT DRAWING OF COOLING SYSTEM 10 28
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 10 30
COMPONENT PARTS OF COOLING SYSTEM 10 31
HD1500 8 00 3
00 INDEX AND FOREWORD INDEX
CONTROL SYSTEM 10 59
LAYOUT DRAWING OF CONTROL SYSTEM 10 59
RETARDER AND HOIST CONTROL SYSTEM 10 62
MACHINE MONITOR SYSTEM 10 64
REARVIEW MONITOR SYSTEM 10 66
KOMTRAX Plus SYSTEM 10 67
PAYLOAD METER SYSTEM 10 72
COMPONENT PARTS OF CONTROL SYSTEM 10 83
HYDRAULIC SYSTEM 10 127
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10 127
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 128
POWER TRAIN SYSTEM 10 163
LAYOUT DRAWING OF POWER TRAIN SYSTEM 10 163
TRANSMISSION CONTROL SYSTEM 10 166
GEAR SHIFT CONTROL SYSTEM 10 172
DIRECTION CONTROL SYSTEM 10 175
KOMATSU TRACTION CONTROL SYSTEM (KTCS) 10 176
TRAVEL SPEED LIMITATION SYSTEM 10 178
COMPONENT PARTS OF POWER TRAIN SYSTEM 10 182
WORK EQUIPMENT SYSTEM 10 238
WORK EQUIPMENT CONTROL 10 238
HOIST CONTROL 10 239
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 241
STEERING SYSTEM 10 248
LAYOUT DRAWING OF STEERING SYSTEM 10 248
FUNCTION OF STEERING SYSTEM 10 249
STEERING COLUMN 10 250
STEERING CONTROL LINKAGE 10 251
COMPONENT PARTS OF STEERING SYSTEM 10 252
BRAKE SYSTEM 10 264
LAYOUT DRAWING OF BRAKE SYSTEM 10 264
RETARDER CONTROL 10 267
ARSC SYSTEM 10 269
COMPONENT PARTS OF BRAKE SYSTEM 10 270
UNDERCARRIAGE AND FRAME 10 299
REAR AXLE SUPPORT 10 299
SUSPENSION 10 300
FRONT SUSPENSION 10 301
REAR SUSPENSION 10 302
FRONT SUSPENSION CYLINDER 10 303
REAR SUSPENSION CYLINDER 10 305
WORK EQUIPMENT 10 306
STRUCTURE OF WORK EQUIPMENT 10 306
CAB AND ITS ATTACHMENTS 10 307
ROPS CAB 10 307
CAB MOUNT 10 308
LIFTING SYSTEM 10 309
POWER LADDER SYSTEM 10 309
00 4 HD1500 8
INDEX 00 INDEX AND FOREWORD
20 STANDARD VALUE TABLE 20 1
ABBREVIATIONS 20 3
STANDARD VALUE TABLE FOR ENGINE 20 8
STANDARD VALUE TABLE FOR ENGINE: HD1500 8 20 8
STANDARD VALUE TABLE FOR MACHINE 20 10
STANDARD VALUE TABLE FOR MACHINE: HD1500 8 20 10
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20 31
30 TEST AND ADJUST 30 1
ABBREVIATIONS 30 6
RELATED INFORMATION TO TEST AND ADJUST 30 11
TOOLS TO TEST AND ADJUST 30 11
ENGINE AND COOLING SYSTEM 30 18
TEST ENGINE SPEED 30 18
TEST EXHAUST GAS COLOR 30 19
TEST BLOWBY PRESSURE 30 22
TEST FUEL PRESSURE 30 24
BLEED AIR FROM FUEL CIRCUIT 30 26
TEST TORQUE CONVERTER STALL SPEED 30 27
POWER TRAIN 30 29
TEST POWER TRAIN OIL PRESSURE 30 29
ADJUST TRANSMISSION INPUT SHAFT SPEED SENSOR 30 44
ADJUST TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR 30 45
ADJUST TRANSMISSION OUTPUT SHAFT SPEED SENSOR 30 46
CHECK AFTER ADJUSTING TRANSMISSION SPEED SENSOR 30 47
FLUSH TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT 30 48
CLEAN FINAL DRIVE CASE MAGNET 30 50
MOVE MACHINE WITH ELECTRICAL SYSTEM PROBLEMS 30 51
STEERING SYSTEM 30 56
TEST STEERING CIRCUIT OIL PRESSURE 30 56
TEST STEERING CYLINDER PRESSURE 30 58
BLEED AIR FROM STEERING CYLINDER CIRCUIT 30 59
BRAKE SYSTEM 30 61
RELEASE PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 30 61
TEST WHEEL BRAKE OIL PRESSURE 30 62
TEST AND ADJUST BRAKE ACCUMULATOR PRESSURE 30 67
TEST AND PRESSURIZE BRAKE ACCUMULATOR WITH NITROGEN GAS 30 70
PROCEDURE TO RELEASE NITROGEN GAS WHEN DISPOSING ACCUMULATOR 30 81
TEST BRAKE PERFORMANCE 30 82
BLEED AIR FROM BRAKE CIRCUIT 30 85
TEST PARKING BRAKE OIL PRESSURE 30 89
RELEASE PARKING BRAKE MANUALLY 30 91
TEST THE AMOUNT OF WHEEL BRAKE DISC WEAR 30 93
HYDRAULIC SYSTEM 30 95
TEST HOIST CIRCUIT OIL PRESSURE 30 95
TEST HOIST CYLINDER SUPPLY PRESSURE 30 97
TEST OIL PRESSURE OF HOIST EPC VALVE CIRCUIT 30 98
TEST AND ADJUST FRONT SUSPENSION CYLINDER 30 100
TEST AND ADJUST REAR SUSPENSION CYLINDER 30 106
BLEED AIR FROM HYDRAULIC CIRCUIT 30 112
CALIBRATION OF LADDER POSITION 30 119
HD1500 8 00 5
00 INDEX AND FOREWORD INDEX
WORK EQUIPMENT 30 120
TEST AND ADJUST DUMP BODY POSITIONER SENSOR 30 120
LOWER THE DUMP BODY MANUALLY 30 122
LIFT THE DUMP BODY MANUALLY 30 123
LIFT THE DUMP BODY WITH BUDDY SYSTEM 30 125
CAB AND ITS ATTACHMENTS 30 128
ADJUST STEERING WHEEL TILT LOCK LEVER 30 128
ADJUST RATTLING OPERATOR’S SEAT 30 129
ADJUST CLEARANCE OF ESCAPE DOOR 30 130
LIFTING SYSTEM 30 132
BLEED AIR FROM POWER LADDER CYLINDER 30 132
ELECTRICAL SYSTEM 30 133
SET AND ADJUST EACH EQUIPMENT 30 133
SET AND OPERATE OF MACHINE MONITOR 30 137
START UP KOMTRAX TERMINAL 30 256
SETTING DEFAULT OF KOMTRAX Plus CONTROLLER 30 261
SETTING DEFAULT OF WIRELESS LAN MODEM 30 263
DOWNLOAD KOMTRAX Plus CONTROLLER DATA 30 265
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED 30 269
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED 30 272
VOLTAGE CIRCUIT OF ENGINE CONTROLLER WORK 30 274
BATTERY DISCONNECT SWITCH WORK 30 275
TEST DIODES 30 276
Pm CLINIC 30 277
Pm CLINIC SERVICE 30 277
PERFORM QUICK Pm 30 289
40 TROUBLESHOOTING 40 1
CONTENTS 40 2
ABBREVIATIONS 40 12
RELATED INFORMATION ON TROUBLESHOOTING 40 17
GENERAL TROUBLESHOOTING POINTS 40 17
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 18
CHECKS BEFORE TROUBLESHOOTING 40 20
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40 23
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 24
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARATION 40 43
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 51
SYMPTOM AND TROUBLESHOOTING NUMBERS 40 53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 56
CONNECTORS LIST AND LAYOUT 40 58
CONNECTOR CONTACT IDENTIFICATION 40 89
T BRANCH BOX AND T BRANCH ADAPTER TABLE 40 131
FUSE LOCATION TABLE 40 137
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 40 143
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT 40 145
FAILURE CODES TABLE 40 151
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40 178
FAILURE CODE [1500L0] 40 178
FAILURE CODE [15B0NX] 40 179
FAILURE CODE [15F0KM] 40 181
00 6 HD1500 8
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [15F0MB] 40 182
FAILURE CODE [15F7KM] 40 183
FAILURE CODE [15G0MW] 40 184
FAILURE CODE [15G7KM] 40 186
FAILURE CODE [15H0MW] 40 187
FAILURE CODE [15J0MW] 40 189
FAILURE CODE [15K0MW] 40 191
FAILURE CODE [15L0MW] 40 193
FAILURE CODE [15M0MW] 40 195
FAILURE CODE [15N0MW] 40 197
FAILURE CODE [15SBL1] 40 199
FAILURE CODE [15SBMA] 40 202
FAILURE CODE [15SCL1] 40 203
FAILURE CODE [15SCMA] 40 206
FAILURE CODE [15SDL1] 40 207
FAILURE CODE [15SDMA] 40 210
FAILURE CODE [15SEL1] 40 211
FAILURE CODE [15SEMA] 40 214
FAILURE CODE [15SFL1] 40 216
FAILURE CODE [15SFMA] 40 219
FAILURE CODE [15SGL1] 40 221
FAILURE CODE [15SGMA] 40 224
FAILURE CODE [15SHL1] 40 226
FAILURE CODE [15SHMA] 40 229
FAILURE CODE [15SJMA] 40 230
FAILURE CODE [2B0QNX] 40 231
FAILURE CODE [2F00KM] 40 232
FAILURE CODE [2G42ZG] 40 234
FAILURE CODE [2G43ZG] 40 235
FAILURE CODE [2G44ZG] 40 236
FAILURE CODE [879AKA] 40 238
FAILURE CODE [879AKB] 40 239
FAILURE CODE [879BKA] 40 240
FAILURE CODE [879BKB] 40 241
FAILURE CODE [879CKA] 40 243
FAILURE CODE [879CKB] 40 244
FAILURE CODE [879EMC] 40 245
FAILURE CODE [879FMC] 40 246
FAILURE CODE [879GKX] 40 247
FAILURE CODE [989D00] 40 248
FAILURE CODE [989X00] 40 249
FAILURE CODE [989Y00] 40 250
FAILURE CODE [AA10NX] 40 251
FAILURE CODE [AB00KE] 40 253
FAILURE CODE [AB00KY] 40 255
FAILURE CODE [B@C6NS] 40 256
FAILURE CODE [B@C7NS] 40 257
FAILURE CODE [B@CENS] 40 258
FAILURE CODE [B@JANS] 40 259
FAILURE CODE [D150KB] 40 260
HD1500 8 00 7
00 INDEX AND FOREWORD INDEX
FAILURE CODE [D150KZ] 40 262
FAILURE CODE [D151KB] 40 264
FAILURE CODE [D151KZ] 40 266
FAILURE CODE [D164KY] 40 268
FAILURE CODE [D19HKZ] 40 269
FAILURE CODE [D19JKZ] 40 271
FAILURE CODE [D19QKZ] 40 272
FAILURE CODE [D1EHKA] 40 274
FAILURE CODE [D1EHKB] 40 275
FAILURE CODE [D1EHKY] 40 276
FAILURE CODE [D1ENKZ] 40 277
FAILURE CODE [D1EPKA] 40 279
FAILURE CODE [D1EPKB] 40 281
FAILURE CODE [D1EPKY] 40 283
FAILURE CODE [D1EQKA] 40 284
FAILURE CODE [D1EQKB] 40 286
FAILURE CODE [D1EQKY] 40 288
FAILURE CODE [D1ERKA] 40 290
FAILURE CODE [D1ERKB] 40 292
FAILURE CODE [D1ERKY] 40 294
FAILURE CODE [D1ESKA] 40 296
FAILURE CODE [D1ESKB] 40 298
FAILURE CODE [D1ESKY] 40 300
FAILURE CODE [D1EWKA] 40 302
FAILURE CODE [D1EWKB] 40 304
FAILURE CODE [D1EWKY] 40 306
FAILURE CODE [D1J0KB] 40 308
FAILURE CODE [D5ZHL6] 40 309
FAILURE CODE [D862KA] 40 311
FAILURE CODE [DAF0KT] 40 312
FAILURE CODE [DAF0MB] 40 313
FAILURE CODE [DAF0MC] 40 314
FAILURE CODE [DAF3KK] 40 315
FAILURE CODE [DAF8KB] 40 317
FAILURE CODE [DAFDKB] 40 318
FAILURE CODE [DAFGMC] 40 320
FAILURE CODE [DAFLKA] 40 321
FAILURE CODE [DAFLKB] 40 323
FAILURE CODE [DAFQKR] 40 325
FAILURE CODE [DAQ0KK] 40 326
FAILURE CODE [DAQ0KT] 40 329
FAILURE CODE [DAQ0MC] 40 330
FAILURE CODE [DAQ1KA] 40 331
FAILURE CODE [DAQ2KK] 40 333
FAILURE CODE [DAQ9KQ] 40 335
FAILURE CODE [DAQLKA] 40 336
FAILURE CODE [DAQLKB] 40 338
FAILURE CODE [DAQQKR] 40 340
FAILURE CODE [DAQRKR] 40 341
FAILURE CODE [DAQRMA] 40 342
00 8 HD1500 8
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DAQV00] 40 343
FAILURE CODE [DAQW00] 40 344
FAILURE CODE [DAZ9KQ] 40 345
FAILURE CODE [DAZQKR] 40 346
FAILURE CODE [DB10KT] 40 347
FAILURE CODE [DB10MC] 40 348
FAILURE CODE [DB11KA] 40 349
FAILURE CODE [DB12KK] 40 352
FAILURE CODE [DB13KK] 40 355
FAILURE CODE [DB19KQ] 40 357
FAILURE CODE [DB1LKA] 40 358
FAILURE CODE [DB1LKB] 40 360
FAILURE CODE [DB1QKR] 40 362
FAILURE CODE [DB1QMA] 40 363
FAILURE CODE [DB1RKR] 40 364
FAILURE CODE [DB2QKR] 40 370
FAILURE CODE [DBBUKM] 40 376
FAILURE CODE [DBBUKR] 40 377
FAILURE CODE [DBP0KM] 40 379
FAILURE CODE [DBP0KT] 40 380
FAILURE CODE [DBP0NR] 40 381
FAILURE CODE [DBP5KP] 40 382
FAILURE CODE [DBPLKA] 40 384
FAILURE CODE [DBPLKB] 40 386
FAILURE CODE [DBPQKR] 40 388
FAILURE CODE [DBPRKR] 40 391
FAILURE CODE [DBPRMA] 40 394
FAILURE CODE [DBPUKR] 40 395
FAILURE CODE [DBPVKR] 40 400
FAILURE CODE [DBPWKR] 40 405
FAILURE CODE [DBPXKR] 40 406
FAILURE CODE [DBV0MC] 40 407
FAILURE CODE [DBV1KK] 40 408
FAILURE CODE [DBV6KB] 40 410
FAILURE CODE [DBV7KB] 40 412
FAILURE CODE [DBVLKA] 40 413
FAILURE CODE [DBVLKB] 40 415
FAILURE CODE [DBVQKR] 40 417
FAILURE CODE [DBVRKR] 40 418
FAILURE CODE [DBVVKR] 40 419
FAILURE CODE [DBVWKR] 40 420
FAILURE CODE [DDAAL6] 40 421
FAILURE CODE [DDD7KX] 40 423
FAILURE CODE [DDDGL4] 40 425
FAILURE CODE [DDDHL4] 40 427
FAILURE CODE [DDTHKA] 40 429
FAILURE CODE [DDTJKA] 40 431
FAILURE CODE [DDTKKA] 40 433
FAILURE CODE [DDTLKA] 40 435
FAILURE CODE [DDTMKA] 40 437
HD1500 8 00 9
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DDTNKA] 40 439
FAILURE CODE [DDTPKA] 40 441
FAILURE CODE [DDU1KA] 40 443
FAILURE CODE [DF10KA] 40 445
FAILURE CODE [DF10KB] 40 449
FAILURE CODE [DGE5KX] 40 452
FAILURE CODE [DGF1KX] 40 454
FAILURE CODE [DGR2KB] 40 456
FAILURE CODE [DGR2L8] 40 457
FAILURE CODE [DGR4KB] 40 459
FAILURE CODE [DGR4L8] 40 460
FAILURE CODE [DGR6KB] 40 462
FAILURE CODE [DGR6L8] 40 463
FAILURE CODE [DGREKB] 40 465
FAILURE CODE [DGREL8] 40 466
FAILURE CODE [DGT1KX] 40 468
FAILURE CODE [DHP4KY] 40 470
FAILURE CODE [DHP4KZ] 40 472
FAILURE CODE [DHP5KY] 40 474
FAILURE CODE [DHP5KZ] 40 476
FAILURE CODE [DHP6KA] 40 478
FAILURE CODE [DHP6KX] 40 480
FAILURE CODE [DHP6KY] 40 482
FAILURE CODE [DHP6KZ] 40 484
FAILURE CODE [DHP7KA] 40 486
FAILURE CODE [DHP7KX] 40 488
FAILURE CODE [DHP7KY] 40 490
FAILURE CODE [DHP7KZ] 40 492
FAILURE CODE [DHQ2KX] 40 494
FAILURE CODE [DHQ4KX] 40 496
FAILURE CODE [DHQ6KX] 40 498
FAILURE CODE [DHT5KX] 40 500
FAILURE CODE [DHT5L6] 40 502
FAILURE CODE [DHT7KX] 40 503
FAILURE CODE [DHT7L6] 40 505
FAILURE CODE [DHT8KX] 40 506
FAILURE CODE [DHT8ZG] 40 508
FAILURE CODE [DHU2KX] 40 509
FAILURE CODE [DHU3KX] 40 511
FAILURE CODE [DHUBKX] 40 513
FAILURE CODE [DHUCKX] 40 515
FAILURE CODE [DHUDKX] 40 517
FAILURE CODE [DHUEKX] 40 519
FAILURE CODE [DHUHKX] 40 521
FAILURE CODE [DHUJKX] 40 523
FAILURE CODE [DHUKKX] 40 525
FAILURE CODE [DHULKX] 40 527
FAILURE CODE [DHUMKX] 40 529
FAILURE CODE [DHUQKX] 40 531
FAILURE CODE [DHUSKX] 40 533
00 10 HD1500 8
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DJF1KA] 40 535
FAILURE CODE [DK30KX] 40 537
FAILURE CODE [DK51L5] 40 539
FAILURE CODE [DK52KX] 40 542
FAILURE CODE [DK53L8] 40 544
FAILURE CODE [DK54KX] 40 546
FAILURE CODE [DK5VKX] 40 548
FAILURE CODE [DK5VMA] 40 550
FAILURE CODE [DK60KX] 40 551
FAILURE CODE [DKH0KX] 40 553
FAILURE CODE [DKH1KX] 40 555
FAILURE CODE [DLF1KA] 40 557
FAILURE CODE [DLF1LC] 40 558
FAILURE CODE [DLF2KA] 40 560
FAILURE CODE [DLF2LC] 40 561
FAILURE CODE [DLF8LC] 40 563
FAILURE CODE [DLF9LC] 40 565
FAILURE CODE [DLFKLC] 40 567
FAILURE CODE [DLFLLC] 40 569
FAILURE CODE [DLT3KA] 40 571
FAILURE CODE [DLT3LC] 40 572
FAILURE CODE [DPQ1KR] 40 574
FAILURE CODE [DPQ1LD] 40 577
FAILURE CODE [DPQ2KR] 40 580
FAILURE CODE [DPQ3KR] 40 583
FAILURE CODE [DPQ4KB] 40 585
FAILURE CODE [DQ11KQ] 40 586
FAILURE CODE [DQ11KR] 40 589
FAILURE CODE [DQ11KT] 40 590
FAILURE CODE [DQ11MA] 40 591
FAILURE CODE [DQ11NR] 40 593
FAILURE CODE [DQ12KQ] 40 594
FAILURE CODE [DQ12KR] 40 597
FAILURE CODE [DQ12KT] 40 598
FAILURE CODE [DQ12MA] 40 599
FAILURE CODE [DQ12NR] 40 601
FAILURE CODE [DQ13KQ] 40 602
FAILURE CODE [DQ13KR] 40 605
FAILURE CODE [DQ13KT] 40 606
FAILURE CODE [DQ13MA] 40 607
FAILURE CODE [DQ13NR] 40 609
FAILURE CODE [DQ14KQ] 40 610
FAILURE CODE [DQ14KR] 40 613
FAILURE CODE [DQ14KT] 40 614
FAILURE CODE [DQ14MA] 40 615
FAILURE CODE [DQ14NR] 40 617
FAILURE CODE [DQ15KQ] 40 618
FAILURE CODE [DQ15KR] 40 621
FAILURE CODE [DQ15KT] 40 622
FAILURE CODE [DQ15MA] 40 623
HD1500 8 00 11
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DQ15NR] 40 625
FAILURE CODE [DQ16KQ] 40 626
FAILURE CODE [DQ16KR] 40 629
FAILURE CODE [DQ16KT] 40 630
FAILURE CODE [DQ16MA] 40 631
FAILURE CODE [DQ16NR] 40 633
FAILURE CODE [DQ17KQ] 40 634
FAILURE CODE [DQ17KR] 40 637
FAILURE CODE [DQ17KT] 40 638
FAILURE CODE [DQ17MA] 40 639
FAILURE CODE [DQ17NR] 40 641
FAILURE CODE [DQ18KQ] 40 642
FAILURE CODE [DQ18KR] 40 645
FAILURE CODE [DQ18KT] 40 646
FAILURE CODE [DQ18MA] 40 647
FAILURE CODE [DQ18NR] 40 649
FAILURE CODE [DR10KA] 40 650
FAILURE CODE [DR20KA] 40 652
FAILURE CODE [DR30KA] 40 654
FAILURE CODE [DR40KA] 40 656
FAILURE CODE [DR50KA] 40 658
FAILURE CODE [DR60KA] 40 660
FAILURE CODE [DSJ0KR] 40 662
FAILURE CODE [DUMBKB] 40 663
FAILURE CODE [DV00KB] 40 664
FAILURE CODE [DV01KB] 40 666
FAILURE CODE [DW2AKA] 40 668
FAILURE CODE [DW2AKB] 40 669
FAILURE CODE [DW2AKY] 40 671
FAILURE CODE [DW2AL1] 40 672
FAILURE CODE [DW2ALH] 40 673
FAILURE CODE [DW2BKA] 40 674
FAILURE CODE [DW2BKB] 40 675
FAILURE CODE [DW2BKY] 40 676
FAILURE CODE [DW2BL1] 40 677
FAILURE CODE [DW2BLH] 40 678
FAILURE CODE [DW2CKA] 40 679
FAILURE CODE [DW2CKB] 40 680
FAILURE CODE [DW2CKY] 40 682
FAILURE CODE [DW2CL1] 40 683
FAILURE CODE [DW2CLH] 40 684
FAILURE CODE [DW4BK4] 40 685
FAILURE CODE [DW4BMA] 40 687
FAILURE CODE [DW72KZ] 40 690
FAILURE CODE [DW73KA] 40 692
FAILURE CODE [DW73KB] 40 694
FAILURE CODE [DW73KY] 40 696
FAILURE CODE [DW7NKZ] 40 697
FAILURE CODE [DW7SKZ] 40 699
FAILURE CODE [DWNJKZ] 40 701
00 12 HD1500 8
INDEX 00 INDEX AND FOREWORD
FAILURE CODE [DWNMKZ] 40 703
FAILURE CODE [DX13KA] 40 705
FAILURE CODE [DX13KB] 40 707
FAILURE CODE [DX13KY] 40 709
FAILURE CODE [DX30K4] 40 710
FAILURE CODE [DX30KA] 40 712
FAILURE CODE [DX30KB] 40 714
FAILURE CODE [DX30KY] 40 716
FAILURE CODE [DX30MA] 40 718
FAILURE CODE [DX33K4] 40 720
FAILURE CODE [DX33KA] 40 722
FAILURE CODE [DX33KB] 40 724
FAILURE CODE [DX33KY] 40 726
FAILURE CODE [DX33MA] 40 728
FAILURE CODE [DX37K4] 40 730
FAILURE CODE [DX37KA] 40 732
FAILURE CODE [DX37KB] 40 734
FAILURE CODE [DX37KY] 40 736
FAILURE CODE [DX37MA] 40 737
FAILURE CODE [DX38K4] 40 739
FAILURE CODE [DX38KA] 40 741
FAILURE CODE [DX38KB] 40 743
FAILURE CODE [DX38KY] 40 745
FAILURE CODE [DX38MA] 40 746
FAILURE CODE [DX42KZ] 40 748
FAILURE CODE [DX43KZ] 40 750
FAILURE CODE [DXH1KA] 40 752
FAILURE CODE [DXH1KB] 40 754
FAILURE CODE [DXH1KY] 40 756
FAILURE CODE [DXH2KA] 40 757
FAILURE CODE [DXH2KB] 40 760
FAILURE CODE [DXH2KY] 40 763
FAILURE CODE [DXH3KA] 40 766
FAILURE CODE [DXH3KB] 40 769
FAILURE CODE [DXH3KY] 40 772
FAILURE CODE [DXH4KA] 40 775
FAILURE CODE [DXH4KB] 40 778
FAILURE CODE [DXH4KY] 40 781
FAILURE CODE [DXH5KA] 40 784
FAILURE CODE [DXH5KB] 40 787
FAILURE CODE [DXH5KY] 40 790
FAILURE CODE [DXH6KA] 40 793
FAILURE CODE [DXH6KB] 40 796
FAILURE CODE [DXH6KY] 40 799
FAILURE CODE [DXH7KA] 40 802
FAILURE CODE [DXH7KB] 40 805
FAILURE CODE [DXH7KY] 40 808
FAILURE CODE [DXHHKA] 40 811
FAILURE CODE [DXHHKB] 40 813
FAILURE CODE [DXHHKY] 40 815
HD1500 8 00 13
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DY30MA] 40 818
FAILURE CODE [DY30MC] 40 821
FAILURE CODE [DY30ME] 40 824
FAILURE CODE [DY32MC] 40 826
FAILURE CODE [F9A1KK] 40 829
FAILURE CODE [F9A2KK] 40 832
FAILURE CODE [F9ALKA] 40 835
FAILURE CODE [F9ALKB] 40 837
FAILURE CODE [F9AUKA] 40 839
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 40 842
E 1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 842
E 2 ALL OF LCD UNIT, LED UNIT, AND METER UNIT ON MACHINE MONITOR DISPLAY NOTHING 40 850
E 3 LCD UNIT ON MACHINE MONITOR DISPLAYS NOTHING 40 853
E 4 BACKLIGHT OF LCD UNIT ON MACHINE MONITOR IS ABNORMAL, (BACKLIGHT GOES OUT OR FLICKERS)
40 855
E 5 LCD ON MACHINE MONITOR DOES NOT DISPLAY PROPERLY 40 857
E 6 METER UNIT DISPLAY ON MACHINE MONITOR IS ABNORMAL 40 859
E 7 NIGHT LIGHTING LAMP OF METER UNIT ON MACHINE MONITOR IS ABNORMAL 40 862
E 8 LED UNIT LAMP ON MACHINE MONITOR IS ABNORMAL 40 865
E 9 NIGHT LIGHTING LAMP OF SWITCH PANEL ON MACHINE MONITOR IS ABNORMAL OR SWITCH DOES
NOT OPERATE PROPERLY 40 867
E 10 2 SWITCHES OPERATION OF SWITCH PANEL ON MACHINE MONITOR DOES NOT FUNCTION 40 869
E 11 SWITCH PANEL BUZZER OF MACHINE MONITOR IS ABNORMAL 40 871
E 12 SOME ITEMS OF GAUGES AND CAUTION LAMPS ON MACHINE MONITOR ARE NOT DISPLAYED
PROPERLY 40 873
E 13 REARVIEW MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40 874
E 14 REARVIEW MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40 876
E 15 REARVIEW MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40 879
E 16 NIGHT LIGHTING LAMP OF REARVIEW MONITOR IS ABNORMAL 40 882
E 17 REARVIEW MONITOR IS NOT DISPLAYED IN CONJUNCTION WITH REVERSE WHEN THE CONSTANT
DISPLAY SETTING IS DISABLED 40 884
E 18 REARVIEW MONITOR REFERENCE LINE IS NOT DISPLAYED WHEN THE REFERENCE LINE DISPLAY
SETTING IS ENABLED 40 887
E 19 FUEL LEVEL GAUGE DOES NOT INDICATE CORRECT LEVEL 40 889
E 20 SEAT BELT CAUTION LAMP INDICATION IS ABNORMAL 40 891
E 21 MACHINE MONITOR CANNOT BE OPERATED WHEN STARTING SWITCH IS IN OFF POSITION 40 893
E 22 ALARM BUZZER DOES NOT SOUND 40 894
E 23 ALARM BUZZER DOES NOT STOP SOUNDING 40 896
E 24 AISS FUNCTION DOES NOT OPERATE PROPERLY 40 898
E 25 HOIST LEVER DOES NOT OPERATE PROPERLY 40 900
E 26 TURN SIGNAL LAMP AND WINKER LAMP (HAZARD LAMP) DO NOT OPERATE PROPERLY 40 902
E 27 NONE OF HEADLAMP, CLEARANCE LAMP, AND TAIL LAMP LIGHTS 40 906
E 28 SMALL LAMP (CLEARANCE LAMP) DOES NOT LIGHT UP 40 909
E 29 TAIL LAMP DOES NOT LIGHT UP 40 912
E 30 HEADLAMP (LOW BEAM) DOES NOT LIGHT UP 40 915
E 31 HEADLAMP (HIGH BEAM) DOES NOT LIGHT UP 40 918
E 32 NEITHER (LOW BEAM) NOR (HIGH BEAM) HEADLAMPS LIGHTS UP 40 921
E 33 HIGH BEAMS DO NOT LIGHT UP WHILE PASSING SWITCH IS OPERATED 40 923
E 34 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40 925
E 35 DATA DOWNLOADING BY USING WIRELESS LAN CAN NOT BE PERFORMED 40 927
00 14 HD1500 8
INDEX 00 INDEX AND FOREWORD
E 36 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 40 928
E 37 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 40 931
E 38 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED 40 936
E 39 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL 40 939
E 40 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR 40 942
E 41 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION 40 944
E 42 EXTERNAL POWER SUPPLY ENGINE OIL PAN HEATER DOES NOT OPERATE 40 945
E 43 EXTERNAL POWER SUPPLY BRAKE TANK HEATER DOES NOT OPERATE 40 947
E 44 EXTERNAL POWER SUPPLY TRANSMISSION OIL PAN HEATER DOES NOT OPERATE 40 949
E 45 EXTERNAL POWER SUPPLY HYDRAULIC TANK HEATER DOES NOT OPERATE 40 951
E 46 BUZZER DOES NOT SOUND WHEN POWER LADDER IS OPERATED 40 953
E 47 POWER LADDER PUMP DOES NOT OPERATE 40 955
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40 957
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40 957
FAILURE MODE AND CAUSE TABLE 40 958
H 1 MACHINE DOES NOT START 40 971
H 2 MACHINE DOES NOT TRAVEL SMOOTHLY (MACHINE HUNTS) 40 974
H 3 LOCKUP IS NOT RELEASED 40 975
H 4 ABNORMALLY STRONG SHOCKS RESULT FROM STARTING OF MACHINE AND GEAR SHIFTING 40 976
H 5 GEAR IS NOT UPSHIFTED 40 978
H 6 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN LOCKUP DRIVE MODE AT ALL GEAR
SPEEDS 40 981
H 7 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING IN TORQUE CONVERTER DRIVE MODE
40 982
H 8 MACHINE LACKS TRAVEL SPEED OR POWER WHEN TRAVELING AT PARTICULAR GEAR SPEED 40 983
H 9 LARGE TIME LAG IS OBSERVED WHEN MACHINE STARTS AND GEAR IS SHIFTED 40 985
H 10 OIL TEMPERATURE OF TORQUE CONVERTER IS HIGH 40 988
H 11 OIL PRESSURE OF TORQUE CONVERTER IS LOW 40 989
H 12 STEERING WHEEL IS HEAVY TO OPERATE 40 990
H 13 STEERING WHEEL CANNOT BE OPERATED 40 991
H 14 STEERING WHEEL WAGGLES 40 992
H 15 FRONT BRAKE DOES NOT APPLY SUFFICIENTLY 40 993
H 16 REAR BRAKE DOES NOT APPLY SUFFICIENTLY 40 995
H 17 DUMP BODY RISING SPEED IS LOW 40 997
H 18 HYDRAULIC DRIFT OF DUMP BODY IS LARGE 40 999
H 19 DUMP BODY DOES NOT MOVE 40 1000
H 20 FAN SPEED IS UNUSUAL (EXCESSIVELY HIGH OR LOW, OR FAN STOPS) 40 1002
H 21 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40 1003
H 22 POWER LADDER DOES NOT MOVE OR ITS SPEED IS LOW 40 1004
50 DISASSEMBLY AND ASSEMBLY 50 1
ABBREVIATIONS 50 6
DISASSEMBLE AND ASSEMBLE RELATED INFORMATION 50 11
HOW TO READ THIS MANUAL 50 11
COATING MATERIALS LIST 50 13
SPECIAL TOOL LIST 50 16
DIAGRAMS OF SPECIAL TOOLS 50 33
ENGINE AND COOLING SYSTEM 50 42
REMOVE AND INSTALL RADIATOR ASSEMBLY 50 42
REMOVE AND INSTALL OIL COOLER ASSEMBLY 50 69
REMOVE AND INSTALL ENGINE ASSEMBLY 50 84
HD1500 8 00 15
00 INDEX AND FOREWORD INDEX
REMOVE AND INSTALL DAMPER ASSEMBLY 50 138
DISASSEMBLE AND ASSEMBLE OF DAMPER ASSEMBLY 50 142
DISASSEMBLE AND ASSEMBLE OF RADIATOR ASSEMBLY 50 149
POWER TRAIN 50 161
REMOVE AND INSTALL FRONT DRIVE SHAFT 50 161
REMOVE AND INSTALL REAR DRIVE SHAFT ASSEMBLY 50 173
REMOVE AND INSTALL TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50 179
DISCONNECT AND CONNECT TORQUE CONVERTER AND TRANSMISSION ASSEMBLY 50 215
DISASSEMBLE AND ASSEMBLE OF TORQUE CONVERTER AND PTO ASSEMBLY 50 240
DISASSEMBLE AND ASSEMBLE OF TRANSMISSION ASSEMBLY 50 277
REMOVE AND INSTALL DIFFERENCIAL ASSEMBLY 50 338
DISASSEMBLE AND ASSEMBLE OF DIFFERENTIAL ASSEMBLY 50 344
REMOVE AND INSTALL FINAL DRIVE CARRIER ASSEMBLY 50 373
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE CARRIER ASSEMBLY 50 378
BRAKE SYSTEM 50 392
REMOVE AND INSTALL FRONT WHEEL HUB AND BRAKE ASSEMBLY 50 392
DISASSEMBLE AND ASSEMBLE OF FRONT WHEEL HUB AND BRAKE ASSEMBLY 50 406
REMOVE AND INSTALL FINAL DRIVE AND REAR BRAKE ASSEMBLY 50 429
DISASSEMBLE AND ASSEMBLE OF FINAL DRIVE AND REAR BRAKE ASSEMBLY 50 431
STEERING SYSTEM 50 467
REMOVE AND INSTALL STEERING VALVE ASSEMBLY 50 467
REMOVE AND INSTALL O RING OF STEERING VALVE ASSEMBLY 50 473
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 50 479
DISASSEMBLE AND ASSEMBLE OF STEERING CYLINDER ASSEMBLY 50 493
UNDERCARRIAGE AND FRAME 50 498
REMOVE AND INSTALL FRONT WHEEL ASSEMBLY 50 498
REMOVE AND INSTALL REAR WHEEL ASSEMBLY 50 504
REMOVE AND INSTALL FRONT SUSPENSION CYLINDER ASSEMBLY 50 512
DISASSEMBLE AND ASSEMBLE OF FRONT SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) 50 526
REMOVE AND INSTALL KING PIN 50 530
REMOVE AND INSTALL REAR SUSPENSION CYLINDER ASSEMBLY 50 533
DISASSEMBLE AND ASSEMBLE OF REAR SUSPENSION CYLINDER ASSEMBLY (CYLINDER WITH BUFFER
RING) 50 540
HYDRAULIC SYSTEM 50 545
REMOVE AND INSTALL FLOW AMPLIFIER VALVE ASSEMBLY 50 545
REMOVE AND INSTALL O RING of FLOW AMPLIFIER VALVE ASSEMBLY 50 560
REMOVE AND INSTALL HOIST VALVE ASSEMBLY 50 566
REMOVE AND INSTALL HOIST CYLINDER HEAD ASSEMBLY 50 581
DISASSEMBLE AND ASSEMBLE OF HOIST CYLINDER ASSEMBLY 50 584
WORK EQUIPMENT 50 596
REMOVE AND INSTALL DUMP BODY ASSEMBLY 50 596
CAB AND ITS ATTACHMENTS 50 606
REMOVE AND INSTALL AIR CONDITIONER ASSEMBLY 50 606
REMOVE AND INSTALL OPERATOR’S SEAT ASSEMBLY 50 623
REMOVE AND INSTALL SEAT BELT 50 628
ELECTRICAL SYSTEM 50 630
REMOVE AND INSTALL RETARDER AND HOIST CONTROLLER ASSEMBLY 50 630
REMOVE AND INSTALL TRANSMISSION CONTROLLER ASSEMBLY 50 632
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY 50 634
00 16 HD1500 8
INDEX 00 INDEX AND FOREWORD
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50 636
REMOVE AND INSTALL KOMTRAX PLUS CONTROLLER ASSEMBLY 50 641
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50 643
REMOVE AND INSTALL REARVIEW CAMERA 50 645
REMOVE AND INSTALL KomVision CAMERA 50 647
REMOVE AND INSTALL KomVision RADAR 50 652
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 50 666
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY 50 668
60 MAINTENANCE STANDARD 60 1
ABBREVIATIONS 60 4
ENGINE AND COOLING SYSTEM 60 9
MAINTENANCE STANDARD OF ENGINE MOUNT 60 9
MAINTENANCE STANDARD OF OUTPUT SHAFT 60 10
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE MOTOR 60 12
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE MOTOR 60 14
POWER TRAIN 60 16
MAINTENANCE STANDARD OF DRIVE SHAFT 60 16
MAINTENANCE STANDARD OF TORQUE CONVERTER AND TRANSMISSION MOUNT 60 18
MAINTENANCE STANDARD OF TORQUE CONVERTER AND PTO 60 19
MAINTENANCE STANDARD OF TORQUE CONVERTER VALVE 60 23
MAINTENANCE STANDARD OF TORQUE CONVERTER REGULATOR VALVE 60 25
MAINTENANCE STANDARD OF TRANSMISSION 60 26
MAINTENANCE STANDARD OF TRANSMISSION CONTROL VALVE 60 32
MAINTENANCE STANDARD OF FORWARD AND REVERSE CLUTCH ECMV AND GEAR SPEED CLUTCH ECMV
60 33
MAINTENANCE STANDARD OF LOCKUP CLUTCH ECMV 60 34
MAINTENANCE STANDARD OF TRANSMISSION LUBRICATION SELECTOR VALVE 60 35
MAINTENANCE STANDARD OF FRONT AXLE 60 36
MAINTENANCE STANDARD OF REAR AXLE 60 37
MAINTENANCE STANDARD OF DIFFERENTIAL 60 38
MAINTENANCE STANDARD OF FINAL DRIVE 60 39
STEERING SYSTEM 60 40
MAINTENANCE STANDARD OF STEERING COLUMN 60 40
MAINTENANCE STANDARD OF STEERING CONTROL LINKAGE 60 41
MAINTENANCE STANDARD OF STEERING CYLINDER 60 44
BRAKE SYSTEM 60 45
MAINTENANCE STANDARD OF FRONT SLACK ADJUSTER 60 45
MAINTENANCE STANDARD OF REAR SLACK ADJUSTER 60 46
MAINTENANCE STANDARD OF FRONT BRAKE AND PARKING BRAKE 60 47
MAINTENANCE STANDARD OF REAR BRAKE AND PARKING BRAKE 60 48
UNDERCARRIAGE AND FRAME 60 49
MAINTENANCE STANDARD OF FRONT SUSPENSION CYLINDER 60 49
MAINTENANCE STANDARD OF REAR SUSPENSION CYLINDER 60 51
MAINTENANCE STANDARD OF REAR AXLE SUPPORT 60 52
HYDRAULIC SYSTEM 60 53
MAINTENANCE STANDARD OF STEERING AND HOIST PUMP 60 53
MAINTENANCE STANDARD OF DRIVE PUMP OF HOIST AND FRONT BRAKE COOLING REMOTE MOTOR 60 57
MAINTENANCE STANDARD OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR 60 59
MAINTENANCE STANDARD OF SERVO VALVE OF DRIVE PUMP OF REAR BRAKE COOLING REMOTE MOTOR
60 61
HD1500 8 00 17
00 INDEX AND FOREWORD INDEX
MAINTENANCE STANDARD OF BRAKE CHARGE PUMP 60 62
MAINTENANCE STANDARD OF FRONT BRAKE COOLING AND POWER TRAIN TRIPLEX PUMP 60 64
MAINTENANCE STANDARD OF FRONT BRAKE COOLING REMOTE PUMP 60 66
MAINTENANCE STANDARD OF REAR BRAKE COOLING REMOTE TRIPLEX PUMP 60 68
WORK EQUIPMENT 60 70
MAINTENANCE STANDARD OF HOIST CYLINDER 60 70
CAB AND ITS ATTACHMENTS 60 71
MAINTENANCE STANDARD OF CAB MOUNT 60 71
80 THE OTHER INFORMATION 80 1
ABBREVIATIONS 80 6
AIR CONDITIONER SYSTEM 80 11
PRECAUTIONS FOR REFRIGERANT 80 11
AIR CONDITIONER COMPONENT 80 12
SPECIFICATIONS OF AIR CONDITIONER 80 14
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80 15
OUTLINE OF REFRIGERATION CYCLE 80 16
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80 18
AIR CONDITIONER UNIT 80 18
COMPONENT PARTS OF AIR CONDITIONER UNIT 80 21
AIR CONDITIONER CONTROLLER 80 25
COMPRESSOR 80 26
CONDENSER 80 27
SENSORS FOR AIR CONDITIONER SYSTEM 80 28
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 80 29
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80 31
AIR CONDITIONER SYSTEM DIAGRAM 80 33
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80 34
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 80 36
TESTING AIR LEAKAGE (DUCT) 80 39
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80 39
TESTING AIR CONDITIONER USING SELF DIAGNOSIS FUNCTION 80 42
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE
MACHINE MONITOR 80 43
TEST VENT (MODE) CHANGEOVER 80 45
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80 45
TESTING FRESH/RECIRC AIR CHANGEOVER 80 46
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80 46
TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 80 47
PROCEDURE TO TEST (TRIPLE) PRESSURE SWITCH FOR REFRIGERANT 80 47
TEST RELAYS 80 49
METHOD FOR TESTING RELAYS 80 49
00 18 HD1500 8
INDEX 00 INDEX AND FOREWORD
AIR CONDITIONER TROUBLESHOOTING CHART 1 80 50
AIR CONDITIONER TROUBLESHOOTING CHART 2 80 51
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80 54
FAILURE CODE [879AKA] 80 55
FAILURE CODE [879AKB] 80 56
FAILURE CODE [879BKA] 80 57
FAILURE CODE [879BKB] 80 58
FAILURE CODE [879CKA] 80 59
FAILURE CODE [879CKB] 80 60
FAILURE CODE [879EMC] 80 61
FAILURE CODE [879FMC] 80 62
FAILURE CODE [879GKX] 80 63
A 1 TROUBLESHOOT POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 80 64
A 2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 80 66
A 3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
80 69
A 4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80 71
TROUBLESHOOTING USING GAUGE PRESSURE 80 73
CONNECTION OF SERVICE TOOL 80 75
METHOD FOR CONNECTING SERVICE TOOL 80 75
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
80 76
HANDLE COMPRESSOR OIL 80 78
METHOD FOR REPLACING DESICCANT 80 80
KomVision SYSTEM 80 82
STRUCTURE AND OPERATION OF KomVision SYSTEM 80 82
PRECAUTIONS FOR KomVision SYSTEM 80 82
LAYOUT DRAWING OF KomVision SYSTEM 80 83
COMPONENT PARTS OF KomVision SYSTEM 80 90
TESTING AND ADJUSTING KomVision SYSTEM 80 100
SET AND OPERATE KomVision MONITOR 80 100
CAMERA CALIBRATION 80 120
RADAR ADJUSTMENT (ONLY FOR MACHINE WITH RADAR) 80 156
TROUBLESHOOTING OF KomVision SYSTEM 80 172
RELATED INFORMATION ON TROUBLESHOOTING 80 172
ELECTRICAL SYSTEM TROUBLESHOOTING PREPARATION 80 172
KomVision SYSTEM TROUBLESHOOTING PROCEDURE 80 175
SYMPTOM AND TROUBLESHOOTING NUMBERS 80 178
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80 179
CONNECTORS LIST AND LAYOUT 80 181
FAILURE CODES TABLE 80 186
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 80 189
FAILURE CODE [D1J0KB] 80 189
FAILURE CODE [DBP0KM] 80 190
FAILURE CODE [DBP0KT] 80 191
FAILURE CODE [DBP0NR] 80 192
FAILURE CODE [DBP5KP] 80 193
FAILURE CODE [DBPLKA] 80 195
FAILURE CODE [DBPLKB] 80 197
FAILURE CODE [DBPQKR] 80 199
HD1500 8 00 19
00 INDEX AND FOREWORD INDEX
FAILURE CODE [DBPRKR] 80 202
FAILURE CODE [DBPRMA] 80 205
FAILURE CODE [DBPUKR] 80 206
FAILURE CODE [DBPVKR] 80 211
FAILURE CODE [DBPWKR] 80 216
FAILURE CODE [DBPXKR] 80 217
FAILURE CODE [DPQ1LD] 80 218
FAILURE CODE [DPQ4KB] 80 221
FAILURE CODE [DQ11KQ] 80 222
FAILURE CODE [DQ11KR] 80 224
FAILURE CODE [DQ11KT] 80 225
FAILURE CODE [DQ11MA] 80 226
FAILURE CODE [DQ11NR] 80 228
FAILURE CODE [DQ12KQ] 80 229
FAILURE CODE [DQ12KR] 80 231
FAILURE CODE [DQ12KT] 80 232
FAILURE CODE [DQ12MA] 80 233
FAILURE CODE [DQ12NR] 80 235
FAILURE CODE [DQ13KQ] 80 236
FAILURE CODE [DQ13KR] 80 238
FAILURE CODE [DQ13KT] 80 239
FAILURE CODE [DQ13MA] 80 240
FAILURE CODE [DQ13NR] 80 242
FAILURE CODE [DQ14KQ] 80 243
FAILURE CODE [DQ14KR] 80 245
FAILURE CODE [DQ14KT] 80 246
FAILURE CODE [DQ14MA] 80 247
FAILURE CODE [DQ14NR] 80 249
FAILURE CODE [DQ15KQ] 80 250
FAILURE CODE [DQ15KR] 80 252
FAILURE CODE [DQ15KT] 80 253
FAILURE CODE [DQ15MA] 80 254
FAILURE CODE [DQ15NR] 80 256
FAILURE CODE [DQ16KQ] 80 257
FAILURE CODE [DQ16KR] 80 259
FAILURE CODE [DQ16KT] 80 260
FAILURE CODE [DQ16MA] 80 261
FAILURE CODE [DQ16NR] 80 263
FAILURE CODE [DQ17KQ] 80 264
FAILURE CODE [DQ17KR] 80 266
FAILURE CODE [DQ17KT] 80 267
FAILURE CODE [DQ17MA] 80 268
FAILURE CODE [DQ17NR] 80 270
FAILURE CODE [DQ18KQ] 80 271
FAILURE CODE [DQ18KR] 80 273
FAILURE CODE [DQ18KT] 80 274
FAILURE CODE [DQ18MA] 80 275
FAILURE CODE [DQ18NR] 80 277
FAILURE CODE [DR10KA] 80 278
FAILURE CODE [DR20KA] 80 280
00 20 HD1500 8
00 INDEX AND FOREWORD
FAILURE CODE [DR30KA] 80 282
FAILURE CODE [DR40KA] 80 284
FAILURE CODE [DR50KA] 80 286
FAILURE CODE [DR60KA] 80 288
FAILURE CODE [DUMBKB] 80 290
FAILURE CODE [DV01KB] 80 291
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 80 293
E 1 KomVision MONITOR DOES NOT LIGHT UP OR BACKLIGHT FLICKERS 80 293
E 2 KomVision MONITOR IMAGES ARE NOT DISPLAYED CLEARLY 80 296
E 3 KomVision MONITOR BRIGHTNESS CANNOT BE ADJUSTED 80 301
E 4 NIGHT LIGHTING LAMP OF KomVision MONITOR IS ABNORMAL 80 304
E 5 PART OF THE CAMERA IMAGE IS NOT DISPLAYED ON THE KomVision MONITOR 80 307
E 6 IMAGE ON KomVision MONITOR IS NOT DISPLAYED PROPERLY AFTER CALIBRATION 80 309
90 CIRCUIT DIAGRAMS 90 1
ABBREVIATIONS 90 3
HYDRAULIC CIRCUIT DIAGRAM 90 8
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 8
HYDRAULIC CIRCUIT DIAGRAM 90 13
HYDRAULIC CIRCUIT DIAGRAM (Rear axle oil circulation specifications) 90 15
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 90 17
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM (Only for machine 40 °C specification) 90 19
HYDRAULIC CIRCUIT DIAGRAM OF BRAKE SYSTEM 90 21
HYDRAULIC CIRCUIT DIAGRAM FOR POWER LADDER 90 23
ELECTRICAL CIRCUIT DIAGRAM 90 25
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90 25
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (1/10) 90 29
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (2/10) 90 31
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (3/10) 90 33
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (4/10) 90 35
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (5/10) 90 37
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (6/10) 90 39
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (7/10) 90 41
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (8/10) 90 43
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (9/10) 90 45
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (10/10) 90 47
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (1/9) 90 49
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (2/9) 90 51
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (3/9) 90 53
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (4/9) 90 55
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (5/9) 90 57
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (6/9) 90 59
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (7/9) 90 61
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (8/9) 90 63
INSIDE CAB ELECTRICAL CIRCUIT DIAGRAM (Only for machine with glass heater, additional heater) (9/9) 90 65
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (1/8) 90 67
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (2/8) 90 69
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (3/8) 90 71
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (4/8) 90 73
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (5/8) 90 75
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (6/8) 90 77
HD1500 8 00 21
00 INDEX AND FOREWORD INDEX
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (7/8) 90 79
ELECTRICAL CIRCUIT DIAGRAM OF MACHINE (8/8) 90 81
INDEX 1 1

DESCRIPTION:

Komatsu HD1500-8 Dump Truck Shop Manual SEN06630-11 – PDF DOWNLOAD

SERIAL NUMBERS 81001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL: